Automatic lubricator LUB 1&2 PM30-615-717-919-1219 PMV717-919 Manual type: User manual Master version no.: 01, GB
Date of issue: March 2012 Distribution: Machine documentation
Contact: ANDRITZ FEED & BIOFUEL A/S Division: Machine documentation Machine responsible: Engineering Glentevej 5-7 6705 Esbjerg, Denmark Phone: +45.72.160-300 Fax: +45.72.160-301 E-mail:
[email protected] www.andritz.com
Confidential document. All rights reserved. No duplication or disclosure to third parties permitted without the written consent of ANDRITZ FEED & BIOFUEL A/S
Table of contents
Contents EXPLANATION OF CHAPTERS AND SYMBOLS
3
INTRODUCTION 4 1.1 Mechanical user manual 1.2 Guidelines for the use of the manual 1.3 Instructions in the use of the manual 1.4 Field of application 1.5 Guarantee 1.6 Manufacturer
4 4 4 5 5 5
FUNCTIONAL DESCRIPTION
6
INSTALLATION AND MAINTENANCE
8
4.1 Machine functioning 4.2 Machine components
5.1 Miscellaneous 5.2 Before installation 5.3 Installation instructions 5.5 Installation chart for drum lubrication of one mill 5.6 Installation chart for drum lubrication of two mills 5.7 Installation chart for drum lubrication of three mills 5.8 Mounting of automatic lubricator 5.9 Connection of grease distribution unit, two-roll-system 5.10 Connection of grease distribution unit, three-roll-system 5.11 Installation of grease sensor 5.12 Setting of grease amount and break time
DIRECTIONS FOR USE
6.1 Safety during use of lubricants 6.2 Application 6.3 Daily checklist
6 7
8 8 8 9 10 11 12 13 15 16 17
18
18 19 20
DISMANTLING 21 8.1 Dismantling and scrapping
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21
Drum LUB March 2012 En rev.01 side 2
Table of contents
EXPLANATION OF CHAPTERS AND SYMBOLS = Introduction
= Safety
= Technical data
= Functional description
= Erection and transport
= Directions for use
= Maintenance
= Dismantling and scrapping
= List of spare parts
= Supplier annexes Subject to all rights! Andritz Feed & Biofuel A/S reserves the right to make changes in illustrations and information in this user manual as a consequence of technical development. Furthermore, any translation is subject to reservations. © Copyright Andritz Feed & Biofuel A/S
Confidential document. All rights reserved. No duplication or disclosure to third parties permitted without the written consent of ANDRITZ FEED & BIOFUEL A/S
Drum LUB March 2012 En rev.01 side 3
INTRODUCTION
INTRODUCTION 1.1 Mechanical user manual This manual is a mechanical user manual, which forms part of Andritz Feed & Biofuel’s technical documentation. It is intended to facilitate the process of getting to know and utilize the machine in the best way possible. The user manual contains important instructions regarding safe and economical use of the machine. Observance of these instructions will minimize risks, repair costs and wasted time and also increase the reliability and life of the machine. In addition to this user manual, the machine fitter is responsible for the elaboration of an installation manual.
1.2 Guidelines for the use of the manual The user manual should be read and used by all the persons, who work with the machine, e.g. in the following areas: • • •
Operation: (erection, remedy of errors during the working procedure, maintenance, removal of operational and auxiliary equipment etc.). Maintenance: (service, inspection, repair etc.). Transport: (machine lifting etc.).
In addition to this user manual, national and local safety prescriptions in force are to be observed.
1.3 Instructions in the use of the manual This user manual has been divided into chapters and sections. Therefore, the table of contents or the index pages at the back of the manual should be consulted in order to provide a general view of the manual. Means: Machinery instruction.
Means: Important information about the most efficient use of the machine.
Means: Reference to another section or appendix. Means: Safety information/warning regarding provisions and prohibitions in order to avoid serious injuries or damage. Means: Prohibition of using the machine in an inappropriate and reckless way as regards safety.
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INTRODUCTION
1.4 Field of application The automatic grease lubricating system is constructed to lubricate the bearings on Andritz Feed & Biofuel’s pellet mills. The automatic grease lubricating system ensures a constant and correct amount of lubricant, which optimizes the functioning of the bearing. When lubricating the bearing correctly in this way, the bearing seal will also be protected against external impurities. The system is controlled by means of an external control. - LUB1 is intended for the automatic greasing of one mill. - LUB 2 is intended for the automatic greasing of two or three mills. The grease temperature has to be min. +5°C to ensure the mechanical functioning of the lubricating system.
1.5 Guarantee The sales contract specifies the guarantee, which Andritz Feed & Biofuel A/S, Denmark, grants from the date of delivery. Wear parts and general wear of the equipment shall not be covered by this guarantee. The standard guarantee does not cover equipment, which has been damaged due to the fact that it was used for other purposes or in other conditions than those, for which it was offered. The standard guarantee does no cover damage, misuse or lack of maintenance, which infringe the recommendations given in the Andritz Feed & Biofuel manuals. Andritz Feed & Biofuel has been very attentive to fabrication and design in order to make the product as safe and reliable as possible. Should you, contrary to expectation, experience problems with your Andritz Feed & Biofuel product, please contact the company, which is responsible for the installation of the equipment, or Andritz Feed & Biofuel. On inquiry please indicate the machine serial number on the machine nameplate.
1.6 Manufacturer DENMARK
ANDRITZ FEED & BIOFUEL A/S Glentevej 5-7 DK-6705 Esbjerg Ø Denmark Tel. +45 72 16 03 00 Fax +45 72 16 03 01 email:
[email protected] www.andritz-fb.com
Confidential document. All rights reserved. No duplication or disclosure to third parties permitted without the written written consent consent of of ANDRITZ ANDRITZ FEED FEED & & BIOFUEL BIOFUEL A/S A/S
Drum LUB March 2012 En rev.01 side 5
FUNCTIONAL DESCRIPTION
FUNCTIONAL DESCRIPTION 4.1 Machine functioning function
The drum lubrication and the controls LUB 1 or LUB 2 constitute a complete lubricating system, which is designed to be mounted on a 208 L grease drum. From here the grease is pumped via a pneumatically driven grease pump to the lubrication points in the mill. The correct distribution of grease is ensured by means of the mechanical grease distribution unit placed on the mill and on the panel, respectively. The system has an independent control that takes care of the presence of sufficient grease in the grease container and the addition of the set amount of grease to the lubrication points (see chapter 5 for setting of grease amounts and break times).
LUB 1
LUB 2
1
4
the Green and yellow buttons lights for each mill in operation. Furthermore, there is a signal display
2 3
5
8
6
7
The grease inlet on the mill varies according to the mill type.
screen.
Secundary grease distribution unit on the mill. The grease is distributed to rolls and bearings via hoses and pipes.
rear end of mill Grease pump. The grease amount per stroke is 2.8 cm3/minute.
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FUNCTIONAL DESCRIPTION 4.2 Machine components Operation box
1
The operation box is used for the setting of lubrication time, break time and grease amount.
Yellow button
2
The yellow button lights, when grease is being added, and it is off during break time. The yellow button for the grease sensor flashes to indicate an empty level.
Green button
3
The green button lights, when the mill is being lubricated. Additional lubrication can be achieved by pushing the green button down for a few seconds. The green button flashes in case of a grease distributor defect.
Grease pump
4
The pneumatically driven grease pump pumps the grease from the grease tank to the primary grease distribution unit at regular intervals.
Primary grease unit
5
The grease pump sends the set grease amount to the primary grease distribution unit that distributes the grease to 1, 2 or 3 of the secondary grease distribution units.
Secondary grease unit
6
The grease is distributed from the secondary grease distribution unit direct to the lubrication points in the mill.
Lubrication point
7
Lubrication of bearings and roll retainer shaft bearing and/or main shaft bearing.
Grease sensor
8
The inductive sensor signals, when it has reached the bottom of the grease tank.
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Drum LUB March 2012 En rev.01 side 7
TRANSPORT AND INSTALLATION
INSTALLATION AND INSTALLTION 5.1 Miscellaneous This chapter contains instructions for correct installation and maintenance of the automatic grease lubricating system for mills. Observance of the below instructions will optimize the functioning of rolls and bearings in the mill, provided that the automatic lubricating system is being maintained correctly. Solvents may never be used for the cleaning of the lubricating system. It is recommended to use compressed air or benzine/kerosene for the cleaning.
5.2 Before installation CHECKLIST
On delivery from Andritz Feed & Biofuel the automatic lubricating system has been assembled and prepared for mounting with the mill. •
Check that all fittings are present.
•
Check that all connection points for grease are clean and clean them, if necessary.
•
Flush grease pipes and hoses with a grease gun to provide passage and check for leaks.
•
Pump grease into the grease connection point and check that the grease reaches the roll/bearing.
•
Check that the grease type in use has the correct viscosity to ensure that the grease can be pumped out to the lubrication points (see the lubricant chart in the mill manual).
5.3 Installation instructions flexible pipe
The lubricator may not be welded direct onto the machine bed, which may cause vibrations. The lubricator can either be mounted onto a frame with vibration dampers or onto a separate rack.
Strip
The pump is connected to panel, power, air and primary grease distribution unit. Power, air and grease pump are to be connected according to the installation chart.
pipe bracket
Correct attachment and adjustment of the grease hoses take place at the end of the installation, taking into consideration the machine setup and possible movable attachment points on the machine. The grease hoses have to be protected against wear by means of flexible pipes and pipe brackets. It is important to avoid bending or squeezing the grease hoses during the installation of the lubricating system.
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Drum LUB March 2012 En rev.01 side 8
TRANSPORT AND INSTALLATION
5.5 Installation chart for drum lubrication of one mill The following installation principle applies to the use of the lubricating system in one pellet mill:
air in
air, adjustable, approx. 3 bar
control grease hose
Grease out to grease distribution unit on mill
Pos. 1 2 3 4 5 6 7
Description (lubricator with counter, 1 mill, complete) Primary grease distribution unit (SSV6-12) Panel Lubrication control Inductive sensor Grease tank, approx. 200 kg Pump Grease sensor, adjustable, 200 l, complete
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Drum LUB March 2012 En rev.01 side 9
TRANSPORT AND INSTALLATION
5.6 Installation chart for drum lubrication of two mills The following installation principle applies to the use of the lubricating system in two pellet mills:
air in air, adjustable, approx. 3 bar
control grease hose
Grease out to grease distribution unit on mill 1
Pos. 1 2 3 4 5 6 7
Grease out to grease distribution unit on mill 2
Description (lubricator with counter, 2 mills, complete) Primary grease distribution unit (SSV6-12) Panel Lubrication control Inductive sensor Grease tank, approx. 200 kg Pump Grease sensor, adjustable, 200 l, complete
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Drum LUB March 2012 En rev.01 side 10
TRANSPORT AND INSTALLATION
5.7 Installation chart for drum lubrication of three mills The following installation principle applies to the use of the lubricating system in three pellet mills: air in air, adjustable, approx. 3 bar
control
grease hose
Grease out to grease distribution unit on mill 1 Grease out to grease distribution unit on mill 2 Grease out to grease distribution unit on mill 3
Pos. 1 2 3 4 5 6 7
Description (lubricator with counter, 3 mills, complete) Primary grease distribution unit (SSV6-12) Panel Lubrication control Inductive sensor Grease tank, approx. 200 kg Pump Grease sensor, adjustable, 200 l, complete
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Drum LUB March 2012 En rev.01 side 11
TRANSPORT AND INSTALLATION
5.8 Mounting of automatic lubricator The drum lubrication system consists of a complete lubricator, which has to be connected to the rotary joint of the grease distributor. The lubricator is accompanied by an inductive sensor. The grease temperature has to be min. +5ºC to ensure the mechanical functioning of the lubricating system. COMPRESSED AIR Grease distribution unit
Compressed air is connected to the air hose at 3-4 bar. On delivery from Andritz Feed & Biofuel the grease distribution unit(s) is/ are mounted on the mill. During maintenance the following facts have to be considered: • • • • •
A complete outlet coupling is placed in the outlets to be used. Plug type (4), which is placed at the piston, is characterized by its bevelled edge. These plugs may never be removed. Plug type (12) may never be replaced by plug type (4). Brass cone (6) must always be used together with a valve-body (7). Brass cone (6) closes the connecting canal (10) and may never be used with plug type (12). In the distribution units SSV6 to SSV22 the outlets 1 and 2 may not be plugged, as a blocking of these outlets may cause a total blocking of the entire grease distribution unit. Fittings and plugs have to be mounted and tightened according to the installation description for the grease distribution unit.
The hose connection to the grease distributor has to be attached in a way that it cannot rotate in case of an overload.
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Pos.
Description
1
Grease distributor SSV-8K
2
Rotary joint
3
Plug
4
Union nut
5
Seal
6
Cutting ring
7
Hose Ø6, 1.5 m
10
Control pin
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TRANSPORT AND INSTALLATION
5.9 Connection of grease distribution unit, two-roll-system access
PM30
Port 4 Roll 1
Port 3 Roll 2 Port 1 bearing for roll retainer shaft
Port 2 Bearing for main shaft PM717 PM919 PM1219
port 1 + 2 Roll 2
port 1 Roll 1
Port 8 bearing for roll retainer shaft
access
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TRANSPORT AND INSTALLATION
PMV717
Port 1 + 2 bearing for roll retainer shaft
PMV919
Port 2 Roll 2
Port 1 Roll 1
Port 8 Bearing for main shaft
access PM615
Port 1+2 bearing for roll retainer shaft
Port 8 Roll 2
Port 7 Roll 1
access
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Drum LUB March 2012 En rev.01 side 14
TRANSPORT AND INSTALLATION
5.10 Connection of grease distribution unit, three-roll-system PM717 PM919
Port 1 + 2 Roll 2
Port 1+2 Roll 1
PM1219
Port 3 Roll 3
Port 8 bearing for roll retainer shaft
access PMV717 PMV919
Port 1 + 2 bearing for roll retainer shaft Port 2 Roll 2
Port 1 Roll 1 Port 5 Roll 3
Port 8 Bearing for main shaft
access
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Drum LUB March 2012 En rev.01 side 15
TRANSPORT AND INSTALLATION
5.11 Installation of grease sensor grease sensor
With a full grease container, the grease sensor plate will be at the top of the container and the inductive sensor will be at the bottom (fig. 1). When the inductive sensor reaches the bottom of the grease container, an alarm will be activated (fig. 2). The sensor pipe has to be placed in the top position (fig. 3) to be able to use the last grease in the grease container. When the inductive sensor reaches the bottom of the grease container again, the alarm will be activated, which means that the container is empty and needs to be replaced (fig. 4).
Fig. 1
Fig. 2
Fig. 3
Fig. 4
DRUM LUBRICATION - GREASE SENSOR, ADJUSTABLE
Pos. 1 2 3 4 5 6 7
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Description Snap ring U22x1,2 DIN471 Pipe for grease sensor Bushing for grease sensor Hexagon head screw M8x20 DIN933 Shaft nut KM8 Inductive sensor XS1-M18MA230 Fitting PG9
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TRANSPORT AND INSTALLATION
5.12 Setting of grease amount and break time When not using a control from Andritz Feed & Biofuel, the customer’s own control has to comply with the values indicated by Andritz Feed & Biofuel as regards lubrication time, break time and grease amount. In case the system is delivered with a control from Andritz Feed & Biofuel, lubrication time, break time and grease amount have been set before delivery. The adjustment procedure for the settings appears from the control manual. Type PM30 PM615 PM717 PM919 PMV717 PMV919
Value counter 5 3 5 5 5 5
Break timer [sec.] 360 650 600 450 600 450
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Alarm timer [sec.] 30-45 30-45 30-45 30-45 30-45 30-45
Grease amount [cm3/24t] 1440 479 864 1152 864 1152
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DIRECTIONS FOR USE
DIRECTIONS FOR USE 6.1 Safety during use of lubricants When handling lubricants, the following rules have to be observed: • • • • •
Avoid excessive and repeated contact with the skin. Absorb the oil by means of technical measures. Change clothes, which have been in contact with oil. Wash and remove the oil from the skin in case of skin contact. Do not allow oil to leak into soil or water. Dispose of lubricants according to the rules in force.
Reference is made to the safety data sheet for the specific product for further details about product safety, toxicity and handling.
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Drum LUB March 2012 En rev.01 side 18
DIRECTIONS FOR USE
6.2 Application The system takes care of lubricating the mill with the correct amount of grease at the right time. The grease is pumped from the grease container (1) to the primary grease distribution unit (2), which is placed on the panel (3). Then the grease is transported further on to the secondary grease distribution unit, which is placed on the mill in question, and from here the grease will be distributed to the various lubrication points. The grease distribution unit is equipped with an inductive sensor (4) that gives an impulse to the control (5) for each dosage of a certain amount of grease. The pump (6) is driven by compressed air and starts, when the magnetic valve (7) is activated. The grease container (tank) has an inductive grease sensor inside (8) that gives a signal to the control, when the grease container is empty, by making an impulse, when it touches the bottom, which results in an alarm to the control.
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DIRECTIONS FOR USE
When the main motor is activated, a timer in the control will start at 360 seconds. When this period has expired, the magnetic valve is activated, which will start up the pump. The pump is active, until the inductive sensor (4) has registered five impulses, after which the pump is deactivated. The count-down of 360 seconds is reset to zero and starts again, when the magnetic valve and the pump are activated.
Alarm
In case five impulses are not registered within 30 seconds after the activation of the magnetic valve and the pump, an alarm will be given to indicate an error in the automatic grease lubrication system. If the alarm is acknowledged by the operator, the pump will start again, and if the five impulses from the inductive sensor are not registered once more within 30 seconds, a new alarm will be given. The alarm will stop the feeder screw in the mill in question. error detection
A blocking somewhere in the system will affect the primary distributor, which will start an alarm.(all pistons in the unit will stand still). The simplicity of the construction makes a blocked access to a lubrication point difficult to ignore. The grease distributor is provided with a marker pin (see below). The marker pin is placed at the end of the piston and follows the motions of the piston. The marker pin for the grease distributor has to move slowly back and forth, when the pump is in operation. Otherwise, the system is blocked somewhere between the grease distributor and the lubrication points. A blocking can also be found by checking the system for leaks of lubricants.
marker pin
6.3 Daily checklist Step
Action
1
Check for leaks in grease distribution unit, grease inlets and grease hoses.
2
Check the functioning of the pump by starting up a manual lubrication by means of the green button.
3
Check that all lubrication points are lubricated with fresh and clean grease.
4
Check that the marker pin can move in the piston of the various grease units.
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DISMANTLING
DISMANTLING 8.1 Dismantling and scrapping At each dismantling of the machine, e.g. in connection with removal or scrapping, the safety rules in force at the time in question must be observed. The dismantling should take place in the opposite order of the mounting. It is important to suspend/support each component properly before loosening its bolted connections. In case of scrapping the machine, all environmentally damaging parts should be isolated and sent to destruction. This applies to the following parts: • • •
Oil Grease from lubricating. Rubber from couplings, seals, etc.
All electrical components should be sent to a recycling plant. The rest of the machine can be cleaned and sent to a scrapdealer. In case the conditioner is resold to another party than Andritz Feed & Biofuel, the seller is responsible that the present manual accompanies the machine to its new owner. For the remounting after a removal it is important to read the chapter ”Transport and installation”.
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Drum LUB March 2012 En rev.01 side 21
